EP0440753A1 - Cadre de bicyclette en materiau sans talons et son procede de fabrication. - Google Patents

Cadre de bicyclette en materiau sans talons et son procede de fabrication.

Info

Publication number
EP0440753A1
EP0440753A1 EP19900905124 EP90905124A EP0440753A1 EP 0440753 A1 EP0440753 A1 EP 0440753A1 EP 19900905124 EP19900905124 EP 19900905124 EP 90905124 A EP90905124 A EP 90905124A EP 0440753 A1 EP0440753 A1 EP 0440753A1
Authority
EP
European Patent Office
Prior art keywords
composite material
fiber composite
continuous fiber
tube
tubes
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP19900905124
Other languages
German (de)
English (en)
Other versions
EP0440753A4 (en
EP0440753B1 (fr
Inventor
Craig D Calfee
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
CALFEE Craig D
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of EP0440753A1 publication Critical patent/EP0440753A1/fr
Publication of EP0440753A4 publication Critical patent/EP0440753A4/en
Application granted granted Critical
Publication of EP0440753B1 publication Critical patent/EP0440753B1/fr
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62K—CYCLES; CYCLE FRAMES; CYCLE STEERING DEVICES; RIDER-OPERATED TERMINAL CONTROLS SPECIALLY ADAPTED FOR CYCLES; CYCLE AXLE SUSPENSIONS; CYCLE SIDECARS, FORECARS, OR THE LIKE
    • B62K19/00—Cycle frames
    • B62K19/18—Joints between frame members
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62K—CYCLES; CYCLE FRAMES; CYCLE STEERING DEVICES; RIDER-OPERATED TERMINAL CONTROLS SPECIALLY ADAPTED FOR CYCLES; CYCLE AXLE SUSPENSIONS; CYCLE SIDECARS, FORECARS, OR THE LIKE
    • B62K19/00—Cycle frames
    • B62K19/02—Cycle frames characterised by material or cross-section of frame members
    • B62K19/16—Cycle frames characterised by material or cross-section of frame members the material being wholly or mainly of plastics

Definitions

  • the present invention relates generally to bicycle frames, and more particularly to bicycle frames of composite materials formed without lugs.
  • bicycle frames have been composed of metal tubes, such as steel, welded into lugs at the tube joints.
  • Non-metal materials for construction of various portions of bicycle frames have also been utilized.
  • a number of manufacturers offer bicycle frames whose tubes are made of woven carbon fibers, for example, c
  • the benefits of using such a material in place of steel is its greater strength-to-weight ratio than steel. The difficulty arises, however, with the bonding of one tube of such material to another.
  • the modulus of elasticity of aluminum is substantially lower than that of most composite materials, including commonly used carbon fiber 5 materials. This means that relatively large, bulky connectors, or lugs, are required to provide the needed strength — at the cost of adding weight to the frame. This also means that the stiffness of the frame is discontinuous at the connections.
  • the present invention provides a bicycle frame and method of manufacturing the same which overcomes the drawbacks enumerated above, as well as others, found in the prior art. This is accomplished by providing a lugless frame construction wherein individual frame tubes are joined together by epoxy-impregnated carbon fiber fabric. Gussets are integrally and simultaneously formed with the joining of the tubes. In this way a strong, lightweight joint is provided without the disadvantages associated with bonding carbon fiber tubes to aluminum connections.
  • the structural members forming the frame are carbon fiber tubes having their fibers oriented in the appropriate direction for each frame tube.
  • the tubes are cut to the appropriate lengths, and mitered to form proper mating between them.
  • Static pressure molds are then positioned for the selected size and geometry of the frame.
  • Epoxy impregnated continuous carbon fiber fabric is then laid into the molds, and the frame tubes laid above the fabric. Additional fabric is then laid above the frame tubes. Preferably this fabric is continuous with the fabric laid below the tubes.
  • the fabric and tube “sandwich” is then compressed in the static pressure molds, at the joints, to form hardened all-carbon fiber joints.
  • Gaps are provided between the mold sections to allow carbon fiber fabric to extend out from the joint during formation. This is generally referred to as "flash" and is trimmed off in most applications.
  • the flash formed in the method of the present invention is trimmed appropriately to form gussets.
  • These gussets are, therefore, integral with the joint, and formed simultaneously therewith.
  • a lugless joint is formed, having continuous fibers and gussets for strength, and carbon-to-carbon laminations for optimal joint characteristics, which is of minimal weight.
  • Fig. 1 shows a bicycle frame built according to the present invention
  • Fig. 2 shows in a perspective view an assembled head tube mold used in the method of the present invention
  • Figs. 3A, 3B, 3C, and 3D show various steps in the process of forming head tube connections according to the present invention
  • Fig. 4 shows in cross-sectional view a head tube connection according to the present invention
  • Figs. 5A, 5B, and 5C show various steps and the result of the process of forming a bottom bracket connection according to the present invention
  • Figs. 6A, 6B, and 6C show the steps and result of the process of forming the seat tube connection according to the present invention.
  • Fig. 1 shows a bicycle frame 10 built according to the present invention.
  • the frame consists of a head tube 12, a seat tube 14, a top tube 16, a bottom bracket shell 18, a down tube 20, two chain stays 22a, 22b, two rear drop-outs 24a, 24b, and two seat stays 26a, 26b.
  • the frame consists further of continuous fiber composite fabric material as discussed further below.
  • Each of the components except the rear drop-outs 24a, 24b will generally be referred to as "tubes" although, as stated below, the components may be of other shapes than tubular.
  • the head tube 12 is connected to the top tube 16 and down tube 20
  • the seat tube 14 is connected to the top tube 16 and bottom bracket shell 18
  • the down tube 20 connected also to the bottom bracket shell 18, each of the chain stays 22a, 22b connected to the bottom bracket shell 18 and one of the rear drop-outs 24a, 24b, and each of the seat stays connected to the seat tube 14 and one of the rear drop ⁇ outs 24a, 24b.
  • This is essentially the arrangement of a traditional bicycle frame. It will be appreciated that fewer or greater numbers of tubes and different tube connections are possible, where appropriate, and such alternate arrangements are not excluded by any aspect of the present invention.
  • a brake bridge 28 may connect the seat stays 28a, 28b between the points where the seat stays 28a, 28b connect to the seat tube 14 and where they connect to the rear drop-outs 24a, 24b.
  • an optional chain stay bridge 30 may connect the chain stays 22a, 22b between the points where the chain stays 22a, 22b connect to the bottom bracket shell 18 and where they connect to the rear drop-outs 24a, 24b.
  • each of the tubes of frame 10 will be a longitudinal member having an annular cross- sectional shape. In appropriate circumstances, however. the tubes may be solid and/or of oval, tear-drop or other selected cross-sectional shape, with the exception that certain of the components, such as head tube 12 and bottom bracket shell 18, must always have cylindrical void extending their internal length to receive rotating members.
  • Each of the tubes will generally be manufactured of a carbon-fiber composite material impregnated with a thermosetting epoxy, resin or other hardening agent.
  • Other fiber materials may be used such as fiberglass, aramid (KevlarTM) , boron, or polyethylene
  • the fibers in the tubes, and the material used to form the joints may be uni-directional tape, woven fabric, braided, or any other process known in the art to align continuous fibers for structural purposes. Further, non-composite materials such as aluminum alloy, titanium, steel, etc. may be used for any of the tubes. In certain applications, the tubes need not be all of a uniform material — they may be selected according to strength, weight and other considerations, as discussed further below. Assembly of frame 10 follows the following general steps. The preparation of the tubes begins by cutting them from stock to a length which is slightly longer than their final length.
  • the ends of the tubes are mitered in such a way that the end of one tube is in relatively complete engagement with the outer surface of the tube to which it is to be joined.
  • the tubes are mitered sufficiently to ensure that each tube is the exact length required.
  • the ends of the tubes are cleaned and sanded in preparation for joining.
  • the apparatus for forming tube joints of a completed bicycle frame include three sets of static pressure molds. The three molds required are: (1) the head tube mold (for joining the top tube, down tube and head tube) ; (2) the seat tube mold (for joining the top tube, seat tube and two seat stays) ; and (3) the bottom bracket mold (for joining the bottom bracket shell, down tube, seat tube and two chain stays) .
  • the molds consist of a number of sections.
  • Fig. 2 shows an example of an assembled head tube mold 100, in perspective, consisting of a bottom half 100a and a top half 100b.
  • a table (not shown) on which the molds are aligned and secured, and a jig (not shown) to attach the rear drop-outs to the appropriate tubes.
  • the molds may be of any suitable material, although those made of metal are preferred since only traditional machining techniques such as milling and polishing are required.
  • the molds may be either fixedly or removably secured to the table, although removably secured molds are preferred to allow the table to be used for a variety of frame sizes and geometries.
  • Figs. 3A through 3D show a number of steps in the process of forming a bicycle frame according to the present invention.
  • Fig. 3A shows the bottom half 100a of head tube mold 100.
  • mold 100 will have a number of cavities 102 and 103 for receiving tube sections.
  • the mold cavities 102 are conic sections.
  • Mold cavity 103 is a cylinder. The largest diameter of the mold cavities 102 is at the end thereof where one tube joins to another tube.
  • the cavities of the mold 100 may first be 8 treated with a mold release material of appropriate type known in the art.
  • plies of continuous carbon-fiber fabric 104 are cut to shape such that when laid in the mold a predetermined amount of overhang extends beyond the cavities.
  • the plies are laid up to a predetermined thickness over bottom half 100a of mold 100.
  • the orientation of the fibers may be arranged such as to control the characteristics of the resulting joint, as described further below.
  • the plies are impregnated with an uncured (“wet") epoxy, either before or after laying up the material in the mold. Alternatively, "pre-preg" (material pre-impregnated with resin) may be used.
  • the tubes (such as head tube 12, top tube 16 and down tube 20) are then placed over their appropriate cavities such that the mitered ends and appropriate tube sections are laid upon the fiber fabric 104. This is shown in Fig. 3C. A portion of the uncured fiber fabric 104 is then laid over the tubes such that the tube joints are in essence pinched between the over lapping fiber fabric. This is shown in Fig. 3D.
  • Fig. 4 shows a cross section of the head tube 12 and its connection to the top tube 16 and the down tube 20.
  • FIG. 5A shows a set of bottom bracket mold sections 112, 114, 116 and 118. Again, mold release is preferably applied to ease separation of the sections once the joint is formed. Carbon fiber fabric c impregnated with uncured epoxy 119 is laid onto the appropriate surface of the mold sections. The bottom bracket shell 18 is fixed in the appropriate position. Next the mitered ends of the down tube 20, seat tube 14, and chain stays 22a and 22b are positioned against the ⁇ bottom bracket shell 18.
  • FIG. 5B shows the mold parts moved into position and secured together as shown in Figure 5B. Once the epoxy has cured, the mold sections are removed and the gussets are trimmed. The resulting joint is shown in Figure 5C.
  • Figure 6A shows the mitered ends of the top tube 16, and of the seat stays 26a and 26b positioned against the top (seat) end region of seat tube 14. Carbon fiber- fabric impregnated with uncured epoxy 123 is laid on the appropriate surfaces of the seat tube mold 0 sections 120a, 120b, 120c.
  • Figure 6B shows the mold sections 120a, 120b, 120c in their secured position.
  • Figure 6C shows the resulting connection, after the removal of the mold sections and the trimming of the gussets.
  • a feature of the present invention is the ability to alter the stiffness of the frame, allowing it to be tailored for the different riding characteristics necessary for various types of riding such as racing and touring. This is done by altering the "lay-up" (e.g., 30 the orientation of the carbon fibers in the tubes and/or joints) prior to or during the frame building process. This tailoring has no affect on the tooling, mitering or molding processes described above.
  • ride and structural characteristics may further be controlled by the introduction of non-fiber tubes, such as titanium, into the frame.
  • the non-fiber tubes may be complete frame tubes or may be sectional inserts, selectively altering the ride and strength characteristics as appropriate.
  • the non-fiber tubes will be used in locations subject to high stress concentrations or local pressure points. One such location is inside the head tube, which is typically heavily loaded by the headset bearing cups. Another possible location is inside the bottom bracket shell which is typically heavily loaded by the bottom bracket bearing cups or sealed bearings.
  • a further feature of the present invention is the ability to build several different sizes of frames from a single set of molds. This is done by simply changing the lengths of the tubes and repositioning the molds on the tables. It is anticipated that holes will exist in the table, allowing the molds to be quickly and simply bolted down in pre-determined positions which ensure proper alignment.
  • One mold table and a few sets of molds can be used to produce a wide variety of frame sizes.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Moulding By Coating Moulds (AREA)
  • Automatic Cycles, And Cycles In General (AREA)
  • Motorcycle And Bicycle Frame (AREA)

Abstract

Un cadre (10) de bicyclette est formé d'un ou plusieurs tubes (14, 16, 20, 22A, 22B, 26A, 26B) en un matériau composite renforcé par des fibres continues. On assemble les tubes sans utiliser de talons en recouvrant les joints (a, b, c, d, e, f, g, h) avec un matériau (104) composite renforcé par des fibres continues et imprégné de résine, puis en serrant les joints dans des moules (100) sous une pression statique. Les couvre-joints (106, 108, 110) forment une partie intégrante des joints. Un ou plusieurs tubes peuvent être métalliques, de préférence en titane. Le cadre de la bicyclette est pourvu de pièces métalliques (24A, 24B), de préférence également en titane.
EP90905124A 1989-03-09 1990-03-06 Cadre de bicyclette en materiau sans talons et son procede de fabrication Expired - Lifetime EP0440753B1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US07/321,510 US5116071A (en) 1989-03-09 1989-03-09 Composite bicycle frame
PCT/US1990/001239 WO1990010570A1 (fr) 1989-03-09 1990-03-06 Cadre de bicyclette en materiau sans talons et son procede de fabrication
US321510 1994-10-12

Publications (3)

Publication Number Publication Date
EP0440753A1 true EP0440753A1 (fr) 1991-08-14
EP0440753A4 EP0440753A4 (en) 1991-10-30
EP0440753B1 EP0440753B1 (fr) 1994-06-08

Family

ID=23250902

Family Applications (1)

Application Number Title Priority Date Filing Date
EP90905124A Expired - Lifetime EP0440753B1 (fr) 1989-03-09 1990-03-06 Cadre de bicyclette en materiau sans talons et son procede de fabrication

Country Status (4)

Country Link
US (2) US5116071A (fr)
EP (1) EP0440753B1 (fr)
DE (1) DE69009726T2 (fr)
WO (1) WO1990010570A1 (fr)

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US10967585B2 (en) 2017-03-16 2021-04-06 Guerrilla Industries LLC Composite structures and methods of forming composite structures
US11572124B2 (en) 2021-03-09 2023-02-07 Guerrilla Industries LLC Composite structures and methods of forming composite structures

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Cited By (4)

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Publication number Priority date Publication date Assignee Title
US10967585B2 (en) 2017-03-16 2021-04-06 Guerrilla Industries LLC Composite structures and methods of forming composite structures
US11745443B2 (en) 2017-03-16 2023-09-05 Guerrilla Industries LLC Composite structures and methods of forming composite structures
US11572124B2 (en) 2021-03-09 2023-02-07 Guerrilla Industries LLC Composite structures and methods of forming composite structures
US12365418B2 (en) 2021-03-09 2025-07-22 Astro Tech Co., Ltd. Composite structures and methods of forming composite structures

Also Published As

Publication number Publication date
EP0440753A4 (en) 1991-10-30
EP0440753B1 (fr) 1994-06-08
USRE35335E (en) 1996-09-24
DE69009726D1 (de) 1994-07-14
DE69009726T2 (de) 1995-01-12
WO1990010570A1 (fr) 1990-09-20
US5116071A (en) 1992-05-26

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Legal Events

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PUAI Public reference made under article 153(3) epc to a published international application that has entered the european phase

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